Installation, use and maintenance instructions

Kerosene burners

One stage operation

CODE MODEL

20148447 RDB 2.2 BX 12 - 18 DGT

20148449 RDB 2.2 BX 18 - 25 DGT

20148451 RDB 2.2 BX 25 - 32 DGT

GB

20148481 (1) - 03/2018

Original instructions

Contents

1 Declarations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Information and general warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Information about the instruction manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.1.2 General dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.1.3 Other symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.1.4 Delivery of the system and the instruction manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Guarantee and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3 Guidance for the use of biofuel blends up to 30%. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.3.1 Information and general instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.3.2 Product Disclaimer Statement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Safety and prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 Technical description of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.1 Models available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.3 Overall dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.4 Burner description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.5 Material supplied separately . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5.1 Notes on safety for the installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5.2 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5.3 Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5.4 Installer/Servicer notes for the use of light oil with bio blends up to 30% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.5 Operating position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.6 Burner assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.7 Securing the burner to the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.8 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135.8.1 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.9 Two-pipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145.9.1 Priming pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.10 One-pipe system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155.10.1 Priming pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.11 Electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.12 Notes on safety for the electrical wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165.12.1 Control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.13 Example of an electrical system without heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5.14 Operating programme without heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.15 Table of timings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.15.1 Operations status indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.15.2 Faults diagnosis - lockouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.15.3 Fuel pre-heating function (for burners equipped with heater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.15.4 Shutdown test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.15.5 Flame detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.15.6 Intermittent operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.15.7 Recycle and limit of repetitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.15.8 Presence of an extraneous light or parasite flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.15.9 Pre and post spark ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.15.10 Reset protection and remote reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.15.11 Reset push-button anomaly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.15.12 External lockout indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215.15.13 Frequency main supply anomaly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1 20148481GB

Contents

5.15.14 Internal voltage anomaly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215.15.15 Checking the fan motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215.15.16 Checking the electronic circuit controlling the oil valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215.15.17 EEprom check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

5.16 Automatic pre-heating deactivation (for burners equipped with heater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

5.17 Programming menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225.17.1 Shutdown test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225.17.2 Light diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225.17.3 Intermittent operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235.17.4 Display of the last lockout that occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

5.18 Lockout types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

6 Start-up, calibration and operation of the burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

6.1 Notes on safety for the first start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

6.2 Combustion adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

6.3 Positioning the electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

6.4 Combustion head adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

6.5 Installation of the graduated index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

6.6 Air damper adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

6.7 Recommended nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276.7.1 Replacing the nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

7.1 Notes on safety for the maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

7.2 Maintenance programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287.2.1 Maintenance frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287.2.2 Safety components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287.2.3 Checking and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

8 Faults / Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

20148481 2 GB

Declarations

1 Declarations

Declaration of conformity in accordance with ISO / IEC 17050-1

Manufacturer: RIELLO S.p.A.

Address: Via Pilade Riello, 737045 Legnago (VR)

Product: Kerosene burners

Model: RDB 2.2 BX 12 - 18 DGTRDB 2.2 BX 18 - 25 DGTRDB 2.2 BX 25 - 32 DGT

These products are in compliance with the following Technical Standards:

EN 276

and according to the European Directives:

MD 2006/42/EC Machine Directive

LVD 2014/35/UE Low Voltage Directive

EMC 2014/30/UE Electromagnetic Compatibility

The quality is guaranteed by a quality and management system certified in accordance with ISO 9001:2015.

Legnago, 01.12.2015 Executive General ManagerRIELLO S.p.A. - Burner Department

Research & Development DirectorRIELLO S.p.A. - Burner Department

Mr. U. Ferretti Mr. F. Comencini

3 20148481GB

Information and general warnings

2.1 Information about the instruction manual

2.1.1 Introduction

The instruction manual supplied with the burner: is an integral and essential part of the product and must not

be separated from it; it must therefore be kept carefully forany necessary consultation and must accompany the burnereven if it is transferred to another owner or user, or toanother system. If the manual is lost or damaged, anothercopy must be requested from the Technical Assistance Ser-vice of the area;

is designed for use by qualified personnel; offers important indications and instructions relating to the

installation safety, start-up, use and maintenance of theburner.

Symbols used in the manual

In some parts of the manual you will see triangular DANGERsigns. Pay great attention to these, as they indicate a situation ofpotential danger.

2.1.2 General dangers

The dangers can be of 3 levels, as indicated below.

2.1.3 Other symbols

Abbreviations used

Ch. ChapterFig. FigurePage PageSec. SectionTab. Table

2 Information and general warnings

DANGER

Maximum danger level!This symbol indicates operations which, if not car-ried out correctly, cause serious injury, death orlong-term health risks.

WARNING

This symbol indicates operations which, if not car-ried out correctly, may cause serious injury, deathor long-term health risks.

CAUTION

This symbol indicates operations which, if not car-ried out correctly, may cause damage to the ma-chine and/or injury to people.

DANGER

DANGER: LIVE COMPONENTS

This symbol indicates operations which, if not car-ried out correctly, lead to electric shocks with le-thal consequences.

DANGER: FLAMMABLE MATERIAL

This symbol indicates the presence of flammablematerials.

DANGER: BURNING

This symbol indicates the risks of burns due tohigh temperatures.

DANGER: CRUSHING OF LIMBS

This symbol indicates the presence of movingparts: danger of crushing of limbs.

WARNING: MOVING PARTS

This symbol indicates that you must keep limbsaway from moving mechanical parts; danger ofcrushing.

DANGER: EXPLOSION

This symbol signals places where an explosive at-mosphere may be present. An explosive atmos-phere is defined as a mixture - under atmosphericconditions - of air and flammable substances inthe form of gases, vapours, mist or dust in which,after ignition has occurred, combustion spreads tothe entire unburned mixture.

PERSONAL PROTECTION EQUIPMENT

These symbols indicate the equipment that mustbe worn and kept by the operator for protectionagainst threats against safety and/or health whileat work.

OBLIGATION TO ASSEMBLE THE COVERAND ALL THE SAFETY AND PROTECTION DE-VICES

This symbol signals the obligation to reassemblethe cover and all the safety and protection devicesof the burner after any maintenance, cleaning orchecking operations.

ENVIRONMENTAL PROTECTION

This symbol gives indications for the use of themachine with respect for the environment.

IMPORTANT INFORMATION

This symbol indicates important information thatyou must bear in mind.

This symbol indicates a list.

20148481 4 GB

Information and general warnings

2.1.4 Delivery of the system and the instruction manual

When the system is delivered, it is important that: the instruction manual is delivered to the user by the system

manufacturer, with the recommendation to keep it in theroom where the heat generator is to be installed.

The instruction manual shows:– the serial number of the burner;

– the address and telephone number of the nearest Assis-tance Centre.

The system supplier must carefully inform the user about:– the use of the system; – any further tests that may be required before activating the

system; – maintenance, and the need to have the system checked at

least once a year by a representative of the manufactureror another specialised technician.To ensure a periodic check, the manufacturer recom-mends the drawing up of a Maintenance Contract.

2.2 Guarantee and responsibility

The Manufacturer guarantees its new products from the date ofinstallation, in accordance with the regulations in force and/or thesales contract. At the moment of the first start-up, check that theburner is integral and complete.

In particular, the rights to the guarantee and the responsibility willno longer be valid, in the event of damage to things or injury topeople, if such damage/injury was due to any of the followingcauses: incorrect installation, start-up, use and maintenance of the

burner; improper, incorrect or unreasonable use of the burner; intervention of unqualified personnel; carrying out of unauthorised modifications on the equipment; use of the burner with safety devices that are faulty, incor-

rectly applied and/or not working; installation of untested supplementary components on the

burner; powering of the burner with unsuitable fuels; faults in the fuel supply system; continuation of use of the burner when a fault has occurred; repairs and/or overhauls incorrectly carried out; modification of the combustion chamber with inserts that

prevent the regular development of the structurally estab-lished flame;

insufficient and inappropriate surveillance and care of thoseburner components most likely to be subject to wear andtear;

use of non-original components, including spare parts, kits,accessories and optional;

force majeure.

The manufacturer furthermore declines any and every re-sponsibility for the failure to observe the contents of thismanual.

The manufacturer’s warranty is subject to correct burner, appli-ance and application matching, and set up in line with Manufac-turer's instructions and guidelines. All components within thehydraulic circuit suitable for biofuel use and supplied by the man-ufacturer will be identified as bio-compatible. No warranty is givenin relation to the use of components which are not so identifiedwith biofuel blends. If in any doubt please contact the manufac-turer for further advice.

If any burners are used with fuel with a bio content >30% then thecomponents within the hydraulic circuit may be affected and arenot covered under warranty. The hydraulic circuit consists of:– pump– hydraulic ram (where applicable)– valve block– flexible oil lines (considered as a consumable component)1 Irrespective of any warranty given by the manufacturer in

relation to normal use and manufacturing defects, whenfuels not meeting the relevant standards are used, or wherefuel storage issues have not been addressed correctly, orthe equipment used is not compatible, if failures occur whichare directly or indirectly attributed to such issues and/or tothe non-observance of this guidance, then no warranty orliability is implied or accepted by the manufacturer.

2 The manufacturer has carefully chosen the specification ofthe bio-compatible components including the flexible oillines to protect the pump, safety value and nozzle. Themanufacturer warranty is dependent upon the use of genu-ine components including the oil lines, being used.

3 The manufacturer warranty does not cover defects arisingfrom incorrect commissioning or servicing by non manufac-turer employed service engineers, and any issues impactingthe burner arising from external site related issues.

.........................................................................................

.........................................................................................

.........................................................................................

.........................................................................................

WARNING

Failure to observe the information given in thismanual, operating negligence, incorrect installa-tion and carrying out of non authorised modifica-tions will result in the annulment by themanufacturer of the guarantee that it supplies withthe burner.

5 20148481GB

Information and general warnings

2.3 Guidance for the use of biofuel blends up to 30%

Introduction

With increasing focus on renewable and sustainable energy re-quirements, biofuel usage is set to increase. The manufacturer iscommitted to promoting energy conservation and the use of re-newable energy from sustainable resources including liquid bio-fuels, however there are some technical aspects that must beconsidered at the planning stage of using such fuels to reduce thepotential for equipment failure or the risks of fuel leakage.

Liquid biofuel is a generic description used for oil that can comefrom numerous feed stocks including recycled cooking oils.These types of oils have to be considered and treated differentlyfrom standard mineral or fossil fuels, as they are generally moreacidic, hydroscopic and less stable.

Due to this, a holistic approach is needed for the specification ofthe liquid biofuel, the storage of the fuel, its oil supply line and an-cillary equipment, and very importantly the oil filtration and theburner itself. The specification for FAME (Fatty Acids Methyl Es-ter) liquid biofuel is critical to reliable equipment operation.

It is a minimum requirement that the fuel blend (up to 30% bio) isobtained with light oil in accordance with the relevant EN stand-ards, regional regulations and FAME in accordance with EN14214. It is also important that the fuel blends meet the environ-mental operating condition requisites of the relative EN stand-ards.

When choosing your oil products where you know biofuels will bein use, please make sure that a bio-compatible burner and/orcomponents have been supplied. If an existing burner is to beused with a liquid biofuel then a kit may be required to make itcompatible and the guidance notes enclosed concerning oil stor-age and filtration must be adhered to. The end user is responsiblefor the thorough verification of the potential risks associated withthe introduction of a biofuel blend and the suitability of the appli-ances and installation applicable.

Irrespective of any warranty given by the manufacturer in relationto normal use and manufacturing defects, when fuels not meetingthe relevant standards are used, or where fuel storage issueshave not been addressed correctly, or the equipment used is notcompatible, if failures occur which are directly or indirectly attrib-uted to such issues and/or to the non-observance of this guid-ance, then no warranty or liability is implied or accepted by themanufacturer.

2.3.1 Information and general instructions

To ensure consistency, the supplier of the fuel must be able todemonstrate compliance with a recognised Quality Control andmanagement system to ensure high standards are maintainedwithin the storage, blending and delivery processes. The installation oil storage tank and its ancillaries must also beprepared BEFORE liquid biofuel is introduced. Checks and preparation should include: For new installations, make sure that all materials and seals

in the oil storage and supply line to the burner are compati-ble with biofuels. For all installations, there must be a goodquality bio-compatible oil filter at the tank and then a sec-ondary filter of 60 Microns protecting the burner from con-tamination.

If an existing oil storage tank is to be used then in addition tothe materials checks as detailed above, it will be essentialthat the tank is first inspected for condition and checked forwater or other contamination. The manufacturer stronglyrecommends that the tank is cleaned and oil filters replacedprior to biofuel delivery. If this is not completed then due to

the hydroscopic nature of biofuel, it will effectively clean thetank, absorb water present which in turn will result in equip-ment failure that is not covered by the manufacturer's war-ranty.

Depending on the capacity of the oil storage tank and oilusage, fuels may remain static within the tank for some con-siderable time and so the manufacturer recommends thatthe oil distributor is consulted regarding the use of additionalbiocides within the fuel to prevent microbial growth fromoccurring within the tank. The manufacturer suggests thatfuel suppliers and or service companies be contacted forguidance on fuel filtration. Special attention should beapplied to duel fuel applications where oil may be stored forlong periods of time.

The burner must be set according to the appliance applica-tion and commissioned checking that all combustion param-eters are as recommended in the appliance technicalmanual.

The manufacturer recommends that the in line and burner oilpump filters are inspected and if required replaced at leastevery 4 months during burner use, before the burner start-up following a long period of discontinue operation and evenmore frequently where contamination has occurred. Particu-lar attention is needed when inspecting and checking forfuel leakages from seals, gaskets and hoses.

2.3.2 Product Disclaimer Statement

CAREFULLY READ THE FOLLOWING DISCLAIMER. YOUACCEPT AND AGREE TO BE BOUND BY THIS DISCLAIMERBY PURCHASING BIO-COMPATIBLE BURNERS AND/ORCOMPONENTS.

Although the information and recommendations (hereinafter “In-formation”) in this guidance is presented in good faith, believed tobe correct and has been carefully checked, the manufacturer(and its subsidiaries) makes no representations or warranties asto the completeness or accuracy of the Information. Informationis supplied upon the condition that the persons receiving samewill make their own determination as to its suitability for their pur-poses prior to use. In no event will the manufacturer (and its sub-sidiaries) be responsible for damages of any nature whatsoeverresulting from the use of or reliance upon Information. Other thanset forth herein, the manufacturer (and its subsidiaries) makes noadditional warranties with respect to the bio-compatible burner,either express or implied, including that of marketability or fitnessfor a particular purpose or use.

In no event shall the manufacturer (and its subsidiaries) be liablefor any indirect, incidental, special or consequential damages in-cluding, without limitation, loss of profits, damages for loss ofbusiness profits, business interruption, loss of business informa-tion, loss of equipment, or other pecuniary loss or compensationfor services whether or not it is advised of the possibility of suchdamages.

With the exception of injuries to persons, the manufacturer's lia-bility is limited to the customer's right to return defective/non-con-forming products as provided by the relevant product warranty.

20148481 6 GB

Safety and prevention

3.1 Introduction

The burners have been designed and built in compliance withcurrent regulations and directives, applying the known technicalrules of safety and envisaging all the potential danger situations.

It is necessary, however, to bear in mind that the imprudent andclumsy use of the equipment may lead to situations of death riskfor the user or third parties, as well as the damaging of the burneror other items. Inattention, thoughtlessness and excessive confi-dence often cause accidents; the same applies to tiredness andsleepiness.

It is a good idea to remember the following: The burner must only be used as expressly described. Any

other use should be considered improper and therefore dan-gerous.

In particular:

it can be applied to boilers operating with water, steam, diather-mic oil, and to other uses expressly foreseen by the manufactur-er;

the type and pressure of the fuel, the voltage and frequency of theelectrical power supply, the minimum and maximum deliveries forwhich the burner has been regulated, the pressurisation of thecombustion chamber, the dimensions of the combustion cham-ber and the room temperature must all be within the values indi-cated in the instruction manual. Modification of the burner to alter its performance and desti-

nations is not allowed. The burner must be used in exemplary technical safety con-

ditions. Any disturbances that could compromise safety mustbe quickly eliminated.

Opening or tampering with the burner components is notallowed, apart from the parts requiring maintenance.

Only those parts envisaged by the manufacturer can bereplaced.

3.2 Personnel training

The user is the person, body or company that has acquired themachine and intends to use it for the specific purpose. He is re-sponsible for the machine and for the training of the people work-ing around it.

The user: undertakes to entrust the machine exclusively to suitably

trained and qualified personnel; undertakes to inform his personnel in a suitable way about

the application and observance of the safety instructions.With that aim, he undertakes to ensure that everyone knowsthe use and safety instructions for his own duties;

Personnel must observe all the danger and caution indica-tions shown on the machine.

Personnel must not carry out, on their own initiative, opera-tions or interventions that are not within their province.

Personnel must inform their superiors of every problem ordangerous situation that may arise.

The assembly of parts of other makes, or any modifications,can alter the characteristics of the machine and hence com-promise operating safety. The manufacturer thereforedeclines any and every responsibility for any damage thatmay be caused by the use of non-original parts.

In addition:

3 Safety and prevention

WARNING

The manufacturer guarantees safety and properfunctioning only if all burner components are intactand positioned correctly.

must take all the measures necessary to pre-vent unauthorised people gaining access tothe machine;

the user must inform the manufacturer iffaults or malfunctioning of the accident pre-vention systems are noticed, along with anypresumed danger situation;

personnel must always use the personal pro-tective equipment envisaged by legislationand follow the indications given in this man-ual.

7 20148481GB

Technical description of the burner

4.1 Models available

Tab. A

4.2 Technical data

Tab. B

(1) Reference conditions: Ambient temperature 20°C - Barometric pressure 1013 mbar - Altitude 0m a.s.l. (Hi = 11.86 kWh/kg)

(2) Values detected during operation.

4.3 Overall dimensions

Tab. C

Tab. D

4 Technical description of the burner

Designation Voltage Code

RDB 2.2 BX 12 - 18 DGT 1/230V/50Hz 20148447

RDB 2.2 BX 18 - 25 DGT 1/230V/50Hz 20148449

RDB 2.2 BX 25 - 32 DGT 1/230V/50Hz 20148451

Model RDB 2.2 BX 12-18 DGT RDB 2.2 BX 18-25 DGT RDB 2.2 BX 25-32 DGT

Delivery (1)Heat output range / Thermal power (1)

kg/hkW

1.0 - 1.512 - 18

1.5 - 2.118 - 25

2.1 - 2.725 - 32

Fuel Kerosene, viscosity 1.6 6mm2/s at 20°C

Electrical supply Single-phase, ~ 50Hz 230V ± 10%

Motor rpmWA

rad/s

280090

0.75294

Capacitor F 4,5

Ignition transformer Secondary 18 kV – 25 mA

Pump (kerosene) Max. pressure 15 bar (217.5 PSI)

Electric power consumption (2) kW 0,16

Protection level IP 20

Net weight kg 9

H

L

G M

EJ

D

P

T

K

*

T

W 3

45

45

W 1

W 2

W9

W8

W5

D 1

Fig. 1

20149391

D1 W1 W2 W3 W5 W8 W9

91 130 150 180 11 72 72

WARNING

* Only for model RDB 2.2 BX 12 - 18

Model D E G H J K L M P TRDB 2.2 BX 12 - 18 DGT 87 172 135 235 75 20 288 153 210 169RDB 2.2 BX 18 - 25 DGT 84 172 135 235 75 20 288 153 210 90RDB 2.2 BX 25 - 32 DGT

20148481 8 GB

Technical description of the burner

4.4 Burner description

1 Oil pump2 Air damper adjustment screw3 Reset button with lockout lamp4 Flame sensor5 Control box6 Pump pressure adjustment screw7 Extension for gauge connection8 Combustion head9 Flange with insulating gasket10 Air inlet11 Motor12 Motor ignition capacitor13 Fuel suction line14 Return line15 Combustion head adjustment handle knob16 Coil17 Air pressure test point18 Recirculating pipe19 Knob

4.5 Material supplied separately

Flue recirculation tube (only for RDB 2.2 BX 12 - 18) . . . . No. 1

Screw of by-pass pump . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 1

1043 17

2

15 11 12

19 8 5

16

6

7

1413

19

18

Fig. 2

20130930

WARNING

The hoses supplied with this burner are not suita-ble for use with light oil containing a bio blend.

In case of use with light oil containing up to 30%bio blend, it will be essential to use flexible oil linessuitable for biofuel use.

Please contact the manufacturer for further infor-mation.

9 20148481GB

Installation

5.1 Notes on safety for the installation

After carefully cleaning all around the area where the burner is tobe installed, and arranging for the environment to be illuminatedcorrectly, proceed with the installation operations.

5.2 Handling

The burner packaging includes a wooden platform, it is thereforepossible to move the burner (still packaged) with a transpallettruck or fork lift truck.

5.3 Preliminary checks

Checking the consignment

Checking the characteristics of the burner

Check the identification label (Fig. 9) of the burner, showing:A the burner modelB the burner typeC the burner code D the serial number of the burnerE the year of manufacture in cryptographic typeF the burner output data (see Firing rate)G the electrical supply and absorption dataH the types of light oil usedI the burner setting

5 Installation

DANGER

All the installation, maintenance and disassemblyoperations must be carried out with the electricitysupply disconnected.

WARNING

The installation of the burner must be carried outby qualified personnel, as indicated in this manualand in compliance with the standards and regula-tions of the laws in force.

DANGER

Combustion air inside the boiler must be free fromhazardous mixes (e.g.: chloride, fluoride, halo-gen); if present, it is highly recommended to carryout cleaning and maintenance more frequently.

WARNING

The handling operations for the burner can behighly dangerous if not carried out with the great-est attention: keep any unauthorised people at adistance; check the integrity and suitableness ofthe available means of handling.Check also that the area in which you are workingis empty and that there is an adequate escapearea (i.e. a free, safe area to which you can quick-ly move if the burner should fall).When handling, keep the load at not more than20-25 cm from the ground.

After positioning the burner near the installationpoint, correctly dispose of all residual packaging,separating the various types of material.

CAUTION

Before proceeding with the installation operations,carefully clean all around the area where the burn-er will be installed.

CAUTION

After removing all the packaging, check the integ-rity of the contents. In the event of doubt, do notuse the burner; contact the supplier.

The packaging elements (wooden cage or card-board box, nails, clips, plastic bags, etc.) must notbe abandoned as they are potential sources ofdanger and pollution; they should be collected anddisposed of in the appropriate places.

WARNING

A burner label that has been tampered with, re-moved or is missing, along with anything else thatprevents the definite identification of the burnermakes any installation or maintenance work diffi-cult.

A B CF

G GED

HI I

Fig. 320114037

20148481 10 GB

Installation

5.4 Installer/Servicer notes for the use of light oil with bio blends up to 30%

When installing the burner, make sure the fuel to be used islight oil. In the case of light oil with a bio blend up to 30%,the latter must comply with the manufacturer specifications(refer to “Technical data” and “Instructions for using biofuelblends up to 30%”).

If a bio blend is in use the installer must seek informationfrom the end user that their fuel supplier can evidence thatthe blends of fuel conform to the relevant standards.

Check that the materials used in the construction of the oiltank and ancillary equipment are suitable for biofuels, If notthese must be upgraded or replaced with bio-compatibleparts.

Particular attention should be given to the oil storage tankand supply to the burner. The manufacturer recommendsthat existing oil storage tanks are cleaned, inspected andany traces of water are removed BEFORE biofuel is intro-duced (contact the tank manufacturer or oil supplier for fur-ther advice). If these recommendations are not respected

this will increase the risk of contamination and possibleequipment failure.

In line oil filters should be replaced making sure that they arebio-compatible. The manufacturer recommends a goodquality bio-compatible oil filter at the tank and a secondary60 micron filter be used to protect the burner pump and noz-zle from contamination.

The burner hydraulic components and flexible oil lines mustbe suitable for biofuel use (check with the manufacturer if indoubt).

The burner must be commissioned and combustion parame-ters set to appliance manufacturer's recommendations.

Regularly check visually for any signs of oil leakage fromseals, gaskets and hoses.

It is strongly recommended that with biofuel use, oil filtersare inspected and replaced every 4 months. More regularlywhere contamination is experienced.

5.5 Operating position

5.6 Burner assembly

WARNING

The burner is designed to work only in position 1.

Installation 1 is preferable, as it is the only one thatallows the maintenance operations as describedin this manual. WARNING

Any other positioning could compromise the cor-rect operation of the appliance.

Installations 2, 3, 4 and 5 are forbidden for safetyreasons.

Fig. 420094131

1 2 3 4 5

CAUTION

The temperature of the incoming air must notexceed 70 °C.

WARNING

For correct BF application, the burner must be in-stalled on an appropriate BF boiler.

B

D5883 Fig. 5

11 20148481GB

Installation

5.7 Securing the burner to the boiler

In order to fix the burner to the boiler, proceed as follows: Insert the screw 2) in the flange 1), and tighten the nut

3)(Fig. 6); Fix the flange 5) to the boiler door 4) using the screws 6)

placing in between the insulating gasket 7)(Fig. 7); Insert the burner, and fix it in place with the nut 8)(Fig. 8).

3

1

2 (M8x30)

Fig. 6

20083624

6 (M8x20) 4

7

5

20083626

Fig. 7

8 (M8)

Fig. 8

20110519

20148481 12 GB

Installation

5.8 Fuel supply

5.8.1 Pump

The pump is designed to allow working with one pipe. For two pipe operation it is necessary to unscrew the return plug2) (Fig. 9), screw the by-pass screw 3) and then screw back onthe plug 2).

Pump pressure

The pump is factory set to the values shown in Tab. K onpage 24.

Key (Fig. 9)1 Gas oil suction line2 Return line3 By-pass screws4 Manometer connection5 Pressure adjuster6 Vacuometer connection7 Gas oil solenoid8 Auxiliary pressure test points

WARNING

Before starting the burner, make sure that the tankreturn line is not clogged.

Obstructions in the line could cause the sealingorgan located on the pump shaft to break.

WARNING

The suction plug 1) is made of plastic. Onceremoved, it must not be used again.

In single-pipe installations, the plug in the re-turn line 2) must be totally in steel.

WARNING

Where light oil containing bio diesel is in use, it isrecommended to avoid over oxygenation of theblended fuels.

Where at all possible avoid the use of two-pipesystems where the circulated fuel is returned tothe tank.

If this cannot be avoided make sure that the returnpipe is normally below the surface of the fuel levelwithin the storage tank.

WARNING

In case of use with light oil containing up to 30%bio blend, it will be essential to use flexible oil linessuitable for biofuel use.

Please contact the manufacturer for further infor-mation.

2

3

5

6

7

1

84

Fig. 9

20083081

13 20148481GB

Installation

5.9 Two-pipe system

The two-pipe vacuum systems (Fig. 10) have a negative fuelpressure (depression) at the burner input.Usually the tank is lower than the burner.

The return line should terminate in the oil tank at the same levelas the suction line; in this case a non-return valve is not required.

Should however the return line arrives over the fuel level, thenon-return valve is indispensable. This solution however is lesssafe than previous one, due to the possibility of leakage of thevalve.

5.9.1 Priming pump

On the system in Fig. 6 switch on the burner and wait for the prim-ing. Should lockout occur prior to the arrival of the fuel, await atleast 20 seconds before repeating the operation.

Tab. EH Difference of levelL Max. length of the suction lineI.D. Internal diameter of the oil pipes

NOTE:Tab. E shows the maximum approximate lengths for the supplyline, depending on the difference in level, length, and the diame-ter of the fuel conduit.

CAUTION

You are advised to use additional filters on the fuelsupply line.

The Manufacturer recommends the use of a goodquality fuel filter on the tank (Fig. 6), and a sec-ondary filter (60 for light oil and 15 for kero-sene) to protect the burner pump and nozzle fromcontamination.

In case of biodiesel use, make sure to install bio-fuel compatible filters.

WARNING

For the 19 kW model it is necessary to put a40 filter instead of 60 filter on the fuel supplyline.

WARNING

Before starting the burner make sure that the re-turn pipe-line is not clogged: any obstructionwould cause the pump seals to break.

WARNING

The pump vacuum should not exceed a maximumof 0.4 bar (30cm Hg).Beyond this limit gas is released from the oil.

Hm

ax. 4

m

H

D10011

Fig. 10

Hmetres

L metres

I.D. (8 mm) I.D. (10 mm)

0 35 100

0.5 30 100

1 25 100

1.5 20 90

2 15 70

3 8 30

3.5 6 20

20148481 14 GB

Installation

5.10 One-pipe system

Pressurised one-pipe systems (Fig. 11) have a positive fuel pres-sure at the burner inlet.

Usually the tank is higher than the burner, or the fuel pumpingsystems are on the outside of the boiler.

The one pipe vacuum systems (Fig. 12) have a negative pres-sure (depression) at the burner inlet.

Usually the tank is lower than the burner.

5.10.1 Priming pump

On the system in Fig. 7 just loosen the plug of the vacuometer6)(Fig. 12) and wait until the fuel comes out.

On the system in Fig. 12 switch on the burner and wait for thepriming. Should lockout occur prior to the arrival of the fuel, awaitat least 20 seconds before repeating the operation.

Tab. F

Tab. GH Difference of levelL Max. length of the suction lineI.D. Internal diameter of the oil pipes

NOTE:Tab. F, and Tab. G the approximate maximum lengths for thesupply pipes, according to the difference of level, length and di-ameter of the fuel line.

CAUTION

You are advised to use additional filters on the fuelsupply line.

The Manufacturer recommends the use of a goodquality fuel filter on the tank (Fig. 12), and a sec-ondary filter (60 for light oil and 15 for kero-sene), to protect the burner pump and nozzle fromcontamination.

In case of biodiesel use, pay attention to installbio-compatible filters.

WARNING

The installer must ensure that the supply pressureis not above 0.5 bar.Above that level, the pump seal is subject to toomuch stress.

Hmetres

L metres

I.D. (8 mm) I.D. (10 mm)

0.5 10 20

1 20 40

1.5 40 80

2 60 100

H

max

. 4m

min

. 0.1

m

D11009

Fig. 11

Hmetres

L metres

I.D. (8 mm) I.D. (10 mm)

0 35 100

0.5 30 100

1 25 100

1.5 20 90

2 15 70

3 8 30

3.5 6 20

H

max

. 4m

D11010

H

Fig. 12

15 20148481GB

Installation

5.11 Electrical wiring

5.12 Notes on safety for the electrical wiring

Before carrying out any maintenance, cleaning or checking oper-ations:

5.12.1 Control box

To remove the control box (Fig. 13) from the burner follow of theinstruction: loosen the screw 1), open the protection 2) and remove all

components. Remove the coil 3) and loosen the two screws 4). Move a little the control box and remove the high voltage

leads.NOTE:the control box is supplied with the jumper 7)(Fig. 14) al-ready installed.

If the control box is installed on a burner with heater, it is neces-sary to remove the jumper 7) before replacing the cover. Connect the heater cables and thermostat as well.

DANGER

The electrical wiring must be carried out with the electrical supply disconnected. Electrical wiring must be carried out by qualified personnel and in compliance with the regulations currently in

force in the country of destination. Refer to the wiring diagrams. The manufacturer declines all responsibility for modifications or connections different from those shown in the wir-

ing diagrams. Do not invert the neutral with the phase in the electrical supply line. Check that the electrical supply of the burner corresponds to that shown on the identification label and in this manual. The burners have been set for intermittent operation. This means they should compulsorily be stopped at least

once every 24 hours to enable the control box to perform checks of its own start-up efficiency. Normally theboiler's thermostat/pressure switch ensures the stopping of the burner.If this is not the case, it is necessary to apply in series with L - N a timer switch that turns off the burner at leastonce every twenty-four hours. Refer to the wiring diagrams.

The electrical safety of the device is obtained only when it is correctly connected to an efficient earthing system,made according to current standards. It is necessary to check this fundamental safety requirement. In the event ofdoubt, have the electrical system checked by qualified personnel.

The electrical system must be suitable for the maximum input power of the device, as indicated on the label and inthe manual, checking in particular that the section of the cables is suitable for the input power of the device.

For the main power supply of the device from the electricity mains:- do not use adapters, multiple sockets or extensions;- use an omnipolar switch, as indicated by the current safety standards.

Do not touch the device with wet or damp body parts and/or in bare feet. Do not pull the electric cables.

DANGER

Disconnect the electrical supply from the burnerby means of the main system switch.

DANGER

Close the fuel interception tap.

DANGER

Avoid condensate, ice and water leaks from form-ing.

After carrying out maintenance, cleaning orchecking operations, reassemble the cover andall the safety and protection devices of the burner.

DANGER

This operation must be performed with the burnerturned off and mains power disconnected.

WARNING

The control box can be used on burners with orwithout a heater. If the heater is damaged, insertthe jumper 7)(Fig. 14) in the control box so thatthe burner can work without the heater until thelatter is replaced.

E9153

4

4

3

12

Fig. 13

7S8792

Fig. 14

20148481 16 GB

Installation

5.13 Example of an electrical system without heater

Key (Fig. 15)

C CapacitatorE Ignition electrodesF Flame sensorMV Fan motor P Short circuit socketRS Remote resetSB Remote lock-out signal (230V - 0.5A max)TB Burner earthTL Heat request thermostatTS Safety thermostatV Oil valveXP5 5- pole socketX5 5 pin plug

~ 50Hz - 230 V

CONTROL BOX

White

Gre

en/Y

ello

w

Blue

BlackWhite

Bla

ck

Red

Gre

y

20068692

T4A

Generalswitch

TO BE DONE BYTHE INSTALLER

CARRIED OUTIN THE FACTORY

Fig. 15

WARNING

Do not invert the neutral with the phase in theelectrical supply line.

Check that the electrical supply of the burnercorresponds to that shown on the identifica-tion label and in this manual.

The section of the conductors must be atleast 1mm2. (Unless otherwise required bylocal guidelines and laws).

WARNING

Test the burner by checking the shutdown of theburner by opening the thermostats and the lockoutby darkening the flame sensor.

CAUTION

If the hood is still present, remove it and pro-ceed with the electrical wiring according tothe wiring diagrams.

Use flexible cables in compliance with the EN60 335-1 standard.

17 20148481GB

Installation

5.14 Operating programme without heater

Normal operation

Lockout due to ignition failure

Lockout due to extraneous light during pre-purging

Key (Fig. 16 - Fig. 17 - Fig. 18)

F Flame sensorHT Heat request thermostat (TL)ID Ignition deviceMV Fan motorSB Remote lockout signalV1 Oil valveLED Reset push-button LED colourts Safety timet1 Standby timet2 Initialisation check timet3 Pre-purge timet3i Pre-ignition timet3l Checks extraneous light during pre-purgingt4i Total spark ignition time t4l Reaction time to achieve safety shutdown due to flame

failuret5i Post- ignition time

* Only 3 consecutive re-ignition attempts are permitted

Loss of flame during operation (Recycle max. 3 attempts)

t1t3

t4i

ts t5i

t4l

HT

FM

ID

V1

F

LED

F

LED

P

M

t3i

POWER SUPPLY

Signal not required

Red

fast

Blin

king

Green

Green Blinking

Orange Blinking

Orange Blinking

Green Blinking

Green

t2

Lockout

D12044

Orangeblinking

Green blinking

Green

Green

Green blinking

Loss of flame during operation (Recycle: max. 3 attempts)

Signal not required

POWER SUPPLY

*

Lockout

Orangeblinking

Fig. 16

Red

fast

blin

kin

g

RedOrange blinking

Green blinking

t2

t1t3

t4i

ts

HT

FM

ID

V1

F

LED

P

M

t5it3i

Lockout

POWER SUPPLY

Red

POWER SUPPLYD11210

Lockout

Orangeblinking

Greenblinking

Fig. 17

t2

t1

P

M

t3l

ts

HT

FM

ID

V1

F

LED

POWER SUPPLY20086216

Lockout

RedGreen, red blinkingGreen

blinking

Orange blinking

Fig. 18

20148481 18 GB

Installation

5.15 Table of timings

5.15.1 Operations status indication

5.15.2 Faults diagnosis - lockouts

Key to layout

Symbol Description Value (sec.)

t0 Standby: the burner is waiting for a heat request -t1 Standby time for an input signal: reaction time, control box remains in waiting status for t1 1t2 Initialisation standby time: check time following the main power start-up 3.5t2l Checks extraneous light during t2: waiting mode for t2l, then lockout: the motor does not start 25t2p Oil pre-heating time : waiting mode for t2p, then there is a lockout (if there is a heater) max 600t3 Pre-purge time: the fan motor is working 15t3l Checks extraneous light during pre-purging: control box goes into lockout at the end of t3l 25t3i Spark pre-ignition time 2ts Safety time 5t4i Total spark ignition time 10t4l Reaction time to achieve safety shutdown due to flame failure 1t5i Spark post-ignition time 3- Minimum time to reset the control box using push-button reset 0.4

Minimum time to reset the control box using remote reset 0.8tr Re-cycles: Max. no. 3 repetitions of complete start-up sequence if there is a flame failure during

operation; the final action at the last attempt following flame failure is a lock-out3

re-cycles

Status Reset push-button colour Seconds Colour code

OFF OFF - - -Pre-heating time (if there is a heater) GREEN flashing 0.5 2.5

Pre-purge ORANGE blinking 0.5 0.5

Safety time GREEN blinking 0.5 0.5

Normal operating position GREEN - - Steady ON

Fault description Reset push-button colour Seconds Colour code

Extraneous light or parasite flame signal GREEN, REDblinking alternately

0.5 0.5

Frequency main supply anomaly ORANGE - - Steady ON Internal voltage fault ORANGE, GREEN

fast blinking alternately0.2 0.2

Reset push-button / Remote reset anomaly GREEN, REDfast blinking alternately

0.2 0.2

Lockout for no flame after Ts RED - - Steady ONLockout due to extraneous light or parasite flame signal RED

blinking0.5 0.5

Lockout for maximum number of recycles (flame failureduring operation)

RED fast blinking

0.2 0.2

Lockout after exceeding max. pre-heating time RED flashing 0.5 2.5

Lockout due to fan motor fault RED, ORANGEflashing inverted

2.5 0.5

Lockout due to malfunction in the internal control circuitthat drives the oil valve

RED, GREENflashing inverted

2.5 0.5

Lockout due to eeprom fault ORANGE, GREENblinking alternately

0.5 0.5

ON OFF Colour code

RED

ORANGE

GREEN

19 20148481GB

Installation

5.15.3 Fuel pre-heating function (for burners equipped with heater)

If the burner is equipped with the fuel pre-heating function, in thepresence of a start request from the heat request thermostat ofthe boiler, the burner awaits the closure of the start-up thermostat(or pre-heating, K) positioned on the nozzle holder.

If the start-up thermostat (or the pre-heating one) does not closewithin 600 seconds, the burner goes into lockout mode.

If the flame goes out during operation, the burner carries out re-cycling if the contact of the start-up thermostat (or the pre-heatingone, K) is closed.

If the flame goes out during operation and the contact of the startup thermostat (or the pre-heating one, K) is open, the purgingstops and the burner waiting for the closure of the contact of thestart up thermostat (or the pre-heating one, K) to restart with thepre-purging time.

5.15.4 Shutdown testIf, during operations, the reset push-button is pressed for longerthan 5 seconds and less than 10 seconds, (so as not to go to thenext menu) the burner switches off, the oil valve closes, the flameis extinguished and the starting sequence restarts.

If the switch off test is enabled, the number of repetitions of thestart up sequence (see section 5.15.7) and the number of possi-ble resets (see section 5.15.11), are reset.

5.15.5 Flame detection

NOTE:With 2 lux, the burner goes into lockout after 3 cycle repeats

5.15.6 Intermittent operation After (at the most) 24 hours of continuous operation, the controlbox starts the automatic switch off sequence, followed by a re-start, in order to check for a possible fault with the flame sensor.

It is possible to set up this automatic switch off to 1 hour, (see thesection 5.17).

5.15.7 Recycle and limit of repetitions

The control box allows a recycle, i.e. complete repetition of thestart-up sequence, making up to 3 attempts, in the event theflame failure during operation.

If the flame failure 4 times during operations, this will cause aburner lockout. If there is a new demand for heat during the recy-cle, the 3 attempts are reset when the limit thermostat (TL)switches.

NOTE:After 510 seconds of continuous operation, a new attempt ofpossibility is added.

By disconnecting the power supply, when a new heat request oc-curs (power supply is applied to the burner) all possible attemptsat re-ignition are reset (maximum 3).

5.15.8 Presence of an extraneous light or parasite flame

If when the fan motor starts, during the pre-purging, an extrane-ous light or parasite flame is detected the burner remains in purg-ing until it disappears or the lockout condition is reached 25seconds.

If the parasite flame or the extraneous light are detected duringthe pre-purging, the pre-purging time of 15 seconds is reset andthe time for checking for the presence of a parasite flame or ex-traneous light begins (the motor continues to purge).

The function is cumulative and can be carried out a maximum of2 times. If at the 24th second the parasite flame or the extraneouslight disappears, the pre-purging time starts and if the parasiteflame or the extraneous light reappear the pre-purging time is re-set and the countdown of 25 seconds for checking for the pres-ence of the parasite flame or the extraneous light restarts.

The third time that the parasite flame or the extraneous light ap-pears the burner goes into lockout.

If during the recycle due to flame disappearance while operatingand the consequent repetition of the start-up sequence the para-site flame or the extraneous light is detected, the countdown of25 seconds starts for checking for the presence of the parasiteflame or the extraneous light.

The presence of the parasite flame or extraneous light is also de-tected in the “t2” state (the burner does not start). The fault is in-dicated by way of the blinking LED (see section 5.15.2).

5.15.9 Pre and post spark ignitionIn the pre-spark ignition time the ignition device starts 2 secondsbefore the oil valve opens.

In the post-spark ignition time, the ignition device stops 3 sec-onds after safety time.

The spark ignition is present during all safety time.

NOTE:In case of continuous recycling or heat requests close toone another, the maximum permissible number of cycle rep-etitions of the ignition transformer is one attempt every min-ute.

5.15.10 Reset protection and remote reset

The system will only unlock after the button has been released.

The unit can also be reset via an external button (remote reset)which connects the L terminal (LINE) to the RESET terminal (re-fer to the wiring diagrams). Max length of external remote resetcable is 3 meters.

5.15.11 Reset push-button anomaly

if the reset push-button or the remote reset breaks or is keptpressed for more than 60 seconds, the fault is indicated by theblinking of the led (see section 5.15.2) as long as the fault is pres-ent.This fault is merely a visualisation. If the fault is detected during pre-purging or safety time, the

burner does not stop (the start-up sequence will continue). If the fault is detected during operation, the burner does

stops and stays stopped with the fault signal active. If the fault is detected during a lockout, the fault is not sig-

nalled and the burner cannot be reset.When the fault disappears, the LED stops blinking.

Flame detection Parameters

Type of sensitive element Photo-conductive cellFunctioning principle Detection of visible lightSensitivity to the flame during thepre-purging

> 1 Lux

Typical sensitivity to the flameduring normal operation

> 3 Lux

Typical sensitivity to the flamefailure

< 2 Lux

20148481 20 GB

Installation

5.15.12 External lockout indicatorThe burner is equipped with an external locking signal function,i.e. to signal (together with the integrated reset push-button) aburner locking alarm.

The control box enables the command of an external lamp byway of the exit (230Vac-0.5Amp max).

5.15.13 Frequency main supply anomaly

The control-box automatically detects the value of the frequencyof the main supply in the range of 50 - 60 Hz, in both cases work-ing times are verified. The fault is indicated by way of the blinkingLED (see section 5.15.2). If the anomaly is detected before heat demand the burner

does not start. If the fault is detected during the pre-purging, the burner

remains in purge condition and the fault is appropriately sig-nalled.

If the anomaly is detected during running position the burnerremains in operation.When the anomaly disappears, the burner restarts.

5.15.14 Internal voltage anomaly

The control-box automatically detects if the internal voltageworks correctly. The fault is indicated by way of the blinking LED(see section 5.15.2). If the anomaly is detected during the initialisation check time,

the burner does not start. If the anomaly is detected after a lockout the burner does not

start. If the anomaly is detected after a shutdown test the burner

does not start. The fault is not detected during normal running, the burner

remains in this state. When the fault disappears, the burner restarts.

5.15.15 Checking the fan motor

The control box automatically detects the presence of the fan mo-tor and, in the event of a fault, it performs a lockout. The lockoutis indicated by the blinking led (see section 5.15.2).

5.15.16 Checking the electronic circuit controlling the oil valve

The control box detects the presence of a fault inside the elec-tronic circuit controlling the oil valve, the fault is indicated by theblinking led (“see section 5.15.2”): if the anomaly is detected during the initialisation, the burner

goes into lockout. if the anomaly is detected during the pre-purging, the burner

goes into lockout. During a recycling, if the fault is detected, the burner does

not start and goes into lockout. If the anomaly is detected during running position the burner

remains in operation.The fault is not detected if the burner is in lockout.

5.15.17 EEprom check

The control-box automatically detects if EEprom memory of mi-crocontroller has failed and will perform a lockout. The lockout isindicated by blinking led (see section 5.15.2).

5.16 Automatic pre-heating deactivation (for burners equipped with heater)

It is possible to disable the pre-heater function in automaticmode by pressing the reset push-button of the control box or theremote reset.

Tab. H

When the pre-heating is disabled, the pre-heating remains offuntil:– a lockout occurs– the main supply voltage is interrupted– there is a stop due to intermittent operation.

The deactivation of the automatic pre-heating function is not lostif the shut-down function is enabled.

Pre-heating deactivationsequence

Colour of the button led

Allow the disabling of the pre-heating onlywhen there is no lockout or fault

-

Allow the disabling of the pre-heating usingthe reset push-button or the remote reset.

-

Supply the burner and simultaneously keeppressed the reset push-button or the remotereset for 3 seconds.

RED

Release the reset push-button or the re-mote reset within 3 seconds.

OFF

The burner will start disabling the pre-heat-ing only if the reset push-button or the re-mote reset is released within 3 seconds.

-

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Installation

5.17 Programming menu

The programming menu can only be accessed via the reset push-button or the remote reset during OPERATION.

If in page menu the reset push-button is not pressed, after 10seconds occur automatic exit and there is a green led blinking forthe value set.

If the number of pressures on the push-button exceeds the max-imum allowable, the value in memory will remain the maximumone.If the push-button or remote reset is pressed for more than 60seconds, a failure of the push-button will be visualised and thecontrol-box will restart.

BLOCK DIAGRAM FOR ENTERING THE MENU

Tab. I

5.17.1 Shutdown test

Sequence for shutdown test Programming allowed in OPERATION. Press the button for 5 sec. t < 10 sec. The RED LED blinks twice (0.2 sec. ON; 0.2 sec. OFF) Release the button The burner will initialise a shutdown followed by a restart

After shutdown, the burner restarts automatically and the numberof recycling attempts is restored.

At the exit of shutdown test page menu there are no leds flashing.

5.17.2 Light diagnosis

Sequence for enable/disable Programming allowed in OPERATION. Press the button for 15 sec. t < 20 sec. GREEN led flashing 2 times Release the button GREEN led OFF Press push-button 1 time for enable or 2 times for disable

function (*) GREEN led ON and OFF at every press and release After 10 sec., the GREEN LED will blink for the number of

times programmed (0.5 sec. ON; 0.5 sec. OFF).

FunctionButton release time

No. of Led blinks per menu page

No. of pressings of the reset push-button

No. of Led blinks (green)

Quitting the menu

Shutdown test 5s t < 10s 2 blinksRED

/none

/none

Automatic, at theend of the blinking

Light diagnosis 15s t < 20s 2 blinksGREEN

1 = enabled 2 = disabled (default)

1 blink2 blink

10 sec. after the release of the button

Intermittent operation

20s t < 25s 3 blinksGREEN

1 = 0 disabled2 = 1 hour 3 = 24 hours (default)

1 blink2 blink3 blink

10 sec. after the release of the button

Last lockout memorised

25s t < 30s 4 blinksGREEN

/none

Displaying the type of lockout accord-ing to the table sec-tion 5.15.2

10 sec. after the release of the button

OPERATION (WITH FLAME)

SWITCHING OFF INTERMITTENTOPERATION

2 RED 2 GREEN 3 GREEN

AUTOMATIC

OUTLET10 SEC. AFTER

RELEASE

10 SEC. AFTER

RELEASE

TESTBRIGHTNESS

DIAGNOSIS 20 SECS.

LAST LOCKOUTMEMORISED

25 SECS.

4 GREEN

10 SEC. AFTER

RELEASE

S9155

5 SECS. 15 SEC.

BURNER STATE

TYPE OF FUNCTION

NUMBER

OUTLET

OF BLINKS

Fig. 19

20148481 22 GB

Installation

5.17.3 Intermittent operation

Sequence for enable/disable Programming allowed in OPERATION. Press the button for 20 sec. t < 25 sec. GREEN led flashing 3 times Release the button GREEN led OFF Press push-button 1 time for disable function (*) Press the button twice to enable a shutdown every 1 hour

(*) Press the button 3 times to enable a shutdown every 24

hours (*) GREEN led ON and OFF at every press and release After 10 sec., the GREEN LED will blink for the number of

times programmed (0.5 sec. ON; 0.5 sec. OFF)

The modification of the intermittent operation setting parametertakes effect:– after the activation of a switch-off test;– after flame disappearance during operation;– after disconnecting and reconnecting the electrical supply.

5.17.4 Display of the last lockout that occurred

The control box allows the last lockout that occurred and hasbeen stored to be displayed, by accessing of see “Programmingmenu” on page 22.

Access to this page is possible only Operating.

Display sequence of the last lockout that occurred Keep the button pressed for 25 sec. = t < 30 sec. The GREEN led blinks 4 times. Release the button. Display of the type of lockout stored for 10 sec.

The display time for the type of lockout can be extended by press-ing the reset push-button during the display of the lockout (thedisplay of the lockout continues for another 10s).

NOTE:(*) Always wait 1 sec. with each pressing and release of thebutton to ensure the command is logged correctly.

5.18 Lockout types

Whenever a lockout occurs, the control box shows the reasonsfor the fault (and the reasons can be identified by the reset push-button colour).

The sequence of pulses issued by the control box of the LED inthe reset push-button identifies the possible types of fault, whichare listed in the table below.

Tab. J

Blinking frequency of the reset push-button for status indication,see “Faults diagnosis - lockouts” on page 19.

Description Lockout time Led colour Probable cause

Presence of extraneous light during standby

After 25 seconds – presence of a false flame signal after heat demand

Pre-heating not terminated (if there is a heater)

After 600 seconds – fault in the resistor of the oil pre-heater– fault in the switch or start-up thermostat– the short-circuit socket is not connected

Presence of extraneous light detected during pre-purging

After 25 seconds – presence of false flame signal during pre-purging

Extraneous light detected during pre-heating (if there is a heater)

After 25 seconds – presence of false flame signal during post-purging

The flame is not detected after the safety time

After 5 secondsfrom oil-valve starts

REDSteady ON

– flame sensor defective or dirty– oil valve defective or dirty– faulty ignition transformer– badly regulated burner– oil fuel not present

Flame failure during opera-tion

After 3 recycles – badly adjusted burner– oil valve defective or dirty– flame sensor defective or dirty

Fan motor error Immediate – faulty fan motor– fan motor not connected

Malfunction in the internal control circuit of the oil valve

Immediate – faulty oil valve– internal control circuit of the oil valve faulty

Eeprom error Immediate – faulty internal memory

WARNING

To reset the control box after visual diagnosticshave been displayed, you must press the resetpush-button or the remote reset.

WARNING

In the event the burner stops, in order to preventany damage to the installation, do not unblock theburner more than twice in a row. If the burnerlocks out for a third time, contact the customerservice.

DANGER

In the event there are further lockouts or faultswith the burner, the maintenance interventionsmust only be carried out by qualified, authorisedpersonnel, in accordance with the contents of thismanual and in compliance with the standards andregulations of current laws.

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Start-up, calibration and operation of the burner

6.1 Notes on safety for the first start-up

6.2 Combustion adjustment

In conformity with EN 267, the application of the burner on theboiler, adjustment and testing must be carried out observing theinstruction manual of the boiler, including verification of the COand CO2 concentration in the flue gases, their temperatures andthe average temperature of the water in the boiler.

Settings carried out in factory

The values in Tab. K refer to 12.50 of CO2, at sea level and witha temperature of the surroundings and the light oil of 20 °C.

Tab. K

(*) Type-approval adjustment

6 Start-up, calibration and operation of the burner

WARNING

The first start-up of the burner must be carried outby qualified personnel, as indicated in this manualand in compliance with the standards and regula-tions of the laws in force. WARNING

Check the correct working of the adjustment, com-mand and safety devices.

WARNING

The combustion air is sucked from outside, there-fore, there can be sensitive temperature varia-tions that can influence the percentage value ofthe CO2. It is advisable to adjust the CO2 accord-ing to the indicated diagram.

e.g. with an external air temperature of 10°C, ad-just the CO2 to 12.5% (± 0.2%).

External air temperature (°C)

% C

O2

D7052

Fig. 20

ModelNozzle

Pump pressure

(± 0.5)

Burner output

Combustion head

adjustment (*) (± 0.5)

Air damper adjustment

(± 0.25)

Model GPH Angle bar kg/h ± 4%mm

(Fig. 22)Set-point(Fig. 24)

RDB 2.2 BX 12 - 18 DGT Danfoss 0.40 80° EH 9 1.26 11 B/1,75

RDB 2.2 BX 18 - 25 DGT Danfoss 0.60 80° EH 8.8 1.81 14 2.3

RDB 2.2 BX 25 - 32 DGT Danfoss 0.75 80° EH 10.3 2.40 19 4.2

20148481 24 GB

Start-up, calibration and operation of the burner

6.3 Positioning the electrodes

Tab. L

6.4 Combustion head adjustment

The combustion head is adjusted in the factory.

Make sure these adjustments comply with the values indicated inTab. K on page 24.

Adjustments on the basis of the required output can be made byrotating the adjustment knob 15)(Fig. 2 on page 9).

1 complete rotation = ~ 1 millimetre.

Tab. M

WARNING

The measurements shown in Fig. 21 must be re-spected.

Model A B C

RDB 2.2 BX 12 - 18 DGTRDB 2.2 BX 18 - 25 DGTRDB 2.2 BX 25 - 32 DGT

4 3 2 - 2.5

±0

.5A

± 0 . 3B

C Fig. 21

20142971

Model X (mm) TURNS D

FULLY CLOSED 0 - 9

RDB 2.2 BX 12 - 18 DGT 2 ~ 2.2 cw 11

RDB 2.2 BX 18 - 25 DGT 5 ~ 5.5 cw 14

RDB 2.2 BX 25 - 32 DGT 10 ~ 11 cw 19

D

X=0

1 m m

X

Fig. 22

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Start-up, calibration and operation of the burner

6.5 Installation of the graduated index

If necessary, the graduated index 1) can be installed or disas-sembled.

Insert the graduated index 1) into the knob and connect it to thepipe 2)(Fig. 23).

6.6 Air damper adjustment

The air damper is factory set to the values indicated in Tab. K onpage 24.

These adjustments are indicative. Each installation however, hasits own unpredictable working conditions: actual nozzle output;positive or negative pressure in the combustion-chamber, theneed of excess air, etc.

All these conditions may require a different air-damper setting.

The damper 1)(Fig. 24) is used to precisely adjust the input airflow rate.

To modify the setting use the screw 2) as shown in Fig. 24.

In the 12 - 18 kW model there is another air damper calibrated inthe factory to notch B (Fig. 24).

2

1

Fig. 23

20142968

1

2 Fig. 24

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Start-up, calibration and operation of the burner

6.7 Recommended nozzles

The burner complies with the emission requirements of the EN267 standard.In order to guarantee that emissions do not vary, recommendedand/or alternative nozzles specified by manufacturer in the In-struction and warning booklet should be used.

To set the delivery range within which the nozzle must work, noz-zle return line fuel pressure must be adjusted.

6.7.1 Replacing the nozzle

To replace the nozzle, proceed as follows (Fig. 25): loosen the nut 1) and take the burner out of the boiler. Loosen the three screws 1)(Fig. 26) from the collar and

remove the blast tube 2); loosen the screw 3) and disconnect the high voltage

cables 4); remove the electrode-stabiliser unit 5); fix the nozzle-holder 6) with the aid of the wrench, then

replace the nozzle 8); loosen the nozzle with the aid of a size 16 wrench, and

replace it; screw in the nozzle again, then reassemble the electrode/

stabiliser unit, respecting the position of the electrodes (seeFig. 21 on page 25).

WARNING

It is advisable to replace nozzles every yearduring regular maintenance operations.

CAUTION

The use of nozzles other than those specified bymanufacturer and inadequate regular mainte-nance may result into emission limits non-con-forming to the values set forth by the regulationsin force, and in extremely serious cases, into po-tential hazards to people and objects.

The manufacturing company shall not be liable forany such damage arising from non-observance ofthe requirements contained in this manual.

DANGER

Turn off the burner’s power supply using the mainsystem switch.

WARNING

Make sure the screw 3)(Fig. 26) is positioned in itsseat 7).

1

Fig. 25

20113969

7

4 6

8

5

21

3

Fig. 26

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Maintenance

7.1 Notes on safety for the maintenance

The periodic maintenance is essential for the good operation,safety, yield and duration of the burner.

It allows you to reduce consumption and polluting emissions andto keep the product in a reliable state over time.

Before carrying out any maintenance, cleaning or checking oper-ations:

7.2 Maintenance programme

7.2.1 Maintenance frequency

7.2.2 Safety componentsThe safety components must be replaced at the end of their lifecycle indicated in Tab. N. The specified life cycles do not refer tothe warranty terms indicated in the delivery or paymentconditions.

Tab. N

7.2.3 Checking and cleaning

Combustion head

Open the burner and make sure that all components of the com-bustion head are in good condition, not deformed by the hightemperatures, free of impurities from the surroundings and cor-rectly positioned.

Boiler

Clean the boiler as indicated in its accompanying instructions inorder to maintain all the original combustion characteristics in-tact, especially the flue gas temperature and combustion cham-ber pressure.

Pump

If the pressure is unstable, or the pump runs noisily, the flexiblehose must be detached from the line filter and the fuel must besucked from a tank located near the burner. This measure per-mits the cause of the anomaly to be traced to either the suctionpiping or the pump.

If the problem lies in the suction line, check the filter is clean andthat air is not entering the piping.

Nozzles

It is advisable to replace nozzles once a year during periodicalmaintenance.

Do not clean the nozzle openings.

7 Maintenance

DANGER

The maintenance interventions and the calibrationof the burner must only be carried out by qualified,authorised personnel, in accordance with the con-tents of this manual and in compliance with thestandards and regulations of current laws.

DANGER

Disconnect the electrical supply from the burnerby means of the main system switch.

DANGER

Close the fuel interception tap.

Wait for the components in contact with heatsources to cool down completely.

The gas combustion system should be checked atleast once a year by a representative of the man-ufacturer or another specialised technician.

Safety component Life cycle

Flame control10 years or 250,000

operation cycles

Flame sensor10 years or 250,000

operation cycles

Gas valves (solenoid)10 years or 250,000

operation cycles

Pressure switches10 years or 250,000

operation cycles

Pressure adjuster 15 years

Servomotor (electronic cam) (if present)

10 years or 250,000operation cycles

Oil valve (solenoid)(if present)

10 years or 250,000operation cycles

Oil regulator (if present)10 years or 250,000

operation cycles

Oil pipes/ couplings (metallic) (if present)

10 years

Flexible hoses (if present)5 years or 30,000 pressurised

cycles

Fan impeller 10 years or 500,000 start-ups

The operator must use the required equipmentduring maintenance.

20148481 28 GB

Maintenance

Filters

Check the filtering baskets on line and at nozzle present in thesystem.

Clean or replace if necessary.

If rust or other impurities are observed inside the pump, use aseparate pump to lift any water and other impurities that mayhave deposited on the bottom of the tank.

Hoses Check periodically the flexible pipes conditions. They have

to be replaced at least every 2 years. In case of use of gas oil and biofuel blends, it is strongly recommended to inspect even more

frequently the hoses and replace them where contaminationhas occurred.

Check to make sure that the hoses are still in good condi-tion.

Fuel tank

If water or contamination is present within the fuel tank, it is es-sential that this is removed before the equipment is to be used.This is extremely important when light oil containing bio diesel isin use. If in doubt about how to achieve this then please contactthe fuel or oil tank supplier.

Cleaning the fan

Proceed as follows: unscrew the screws 1)(Fig. 27) and take out the air damper

2); loosen the screws 3) and take out the suction inlet 4); clean the fan and the inside of the suction inlet, using a suit-

able brush and compressed air. If necessary, carefully disassemble the fan (Fig. 28).

When reinstalling, follow the above indications in reverse order;put all the burner components back in their original positions.

Air damper

Inside the suction casing 2)(Fig. 27) there is a damper that opensdue to the effect of the depression generated when operating.The device interrupts the natural flow of air from the burner to theboiler and vice-versa during stop phases.

It is important to periodically check the device and clean if thereare accumulations of dust that can obstruct the regular openingand closing of the damper.

WARNING

The hoses supplied with this burner are notsuitable for use with light oil containing a bioblend.In case of use with light oil containing up to 30%bio blend, it will be essential to use flexible oil linessuitable for biofuel use. Please contact the manufacturer for furtherinformation.

WARNING

Check to make sure that no dust has accumulatedinside the fan or on its blades, as this condition willcause a reduction in the air flow rate and provokepolluting combustion.

When performing these operations, take care notto damage the fan.

WARNING

It is essential to respect position B)(Fig. 28), indi-cated in the table.

3

2

14

Fig. 27

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Maintenance

Combustion

Carry out an analysis of the combustion flue gases.

Significant differences with respect to the previous measure-ments indicate the points where most care should be exercisedduring maintenance.

In case the combustion values found at the beginning of the inter-vention do not respect the standards in force or, in any case, donot correspond to a proper combustion, contact the Technical As-sistant in order to carry out the necessary adjustments.

Let the burner run at full capacity for about ten minutes, setting allthe elements correctly as explained in this manual.

Then carry out the analysis of the combustion by checking:• Smoke temperature at the flue;• CO2 content (%);• CO content (ppm);• Smoke value according to opacity smokes index according to

Bacharach scale.

Tab. O

Model B

All models 51 ± 0.2mm

B

3

Fig. 28D9922

Fan

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Faults / Solutions

Here below you can find some causes and the possible solutionsfor some problems that could cause a failure to start or incorrectoperation of the burner.

A fault usually makes the lockout led signal which is situated in-side the reset push-button of the control box.

When the lockout lamp comes on, the burner will only attempt tostart up after the reset push-button has been pressed. If ignitionis then normal, the stop can be attributed to a temporary fault thatis not dangerous.

If however the lock out continues the cause must be determinedand the solution found.

Tab. P

8 Faults / Solutions

Faults Possible causeFault

diagnosticsSolutions

The burner does notstart when there is heatdemand.

Lack of electrical supply. OFF Check presence of voltage in the L - N the pin plug.

Check the conditions of the fuses.

Check that safety thermostat is not lock out.

The flame sensor sees false light. Eliminate the extraneous light.

The connections in the control boxare wrongly inserted.

OFF Check and connect all the plugs and sockets prop-erly.

The heater is faulty or the P short-cir-cuit socket is not connected (if thereis not a heater).

Replace them.

The burner goes intolockout mode before orduring the pre-purging.

The flame sensor sees extraneouslight.

Eliminate the extraneous light.

Burner runs normally inthe pre-purge and igni-tion cycle and locks outafter 5 seconds ca.

The flame sensor is dirty. REDSteady ON

Clear it.

The flame sensor is faulty. Replace it.

Flame moves away or fails. Check pressure and output of the fuel.

Check air output.

Change nozzle.

Check the coil of solenoid valve.

Burner starts with an ig-nition delay.

The ignition electrodes are wronglypositioned.

OFF Adjust them according to the instructions of thismanual.

Air output is too high. Set the air output according to the instructions ofthis manual.

Nozzle dirty or worn. Replace it.

WARNING

The manufacturer cannot accept responsibility forany damage to persons, animals or property dueto error in installation or in the burner adjustment,or due to improper or unreasonable use or nonobservance of the technical instruction enclosedwith the burner, or due to the intervention of un-qualified personnel.

31 20148481GB

Subject to modifications

RIELLO S.p.A.

I-37045 Legnago (VR)

Tel.: +39.0442.630111

http:// www.riello.it

http:// www.riello.com